6. Now add the driven element outer half element assembly completed in previous steps to the 1-1/2"
sections using 8-32 x 1-3/4" screws and locknuts. Repeat for the other element half.
7
. LINEAR LOADING ROD INSTALLATION (FOR BOTH ELEMENT HALVES)
Place each element assembly on a level surface with the support post up. FROM THE ELEMENT
BUTT SIDE, feed a 3/16” diameter LINEAR LOADING ROD through the flat support insulator.
Then insert the rod into the LL ARM. The rod should protrude just 1/2” through each arm. Tighten the
8-32 x 1/4" set screw and repeat for the other rod. Install a SHAFT RETAINERs, on these rod tips and
snug up against the LL arms. Repeat for the other element half. Repeat this step for each element.
NOTE: to start the RETAINER, hold the 3/8 x 3" PUSH TUBE in your hand with one end between your
thumb and forefinger. Now center the retainer on this end, “dish” into tube, and hold in place with the
same thumb and forefinger. Grasp the linear loading rod near the end with your other hand and firmly
push the retainer onto the rod.
8. SHORTING BAR PREPARATION
Locate the 16 shorting bar halves. Assemble the shorting bars with 8-32 x 1” screws and locknuts.
Finger tighten the locknuts for now. Next, begin to assemble the phyllistrand tension lines as shown
on the ELEMENT HARDWARE drawing. On each shorting bar, insert one end of each length of
PHILLISTRAN HPTG-1200 CORD into the CENTER hole of the shorting bar. Loop the cord AROUND
THE STRAIN RELIEF back through the other hole and allow about 2” to pertrude. Place a cable clip
here as a “backup” to the final clamping action of the shorting bar halves. Don’t tighten the hardware at
this time.
(OPTIONAL)> On each phyllistrand tension line insert two more 1/8” cable clips and allow them to
slide all the way to the shorting bar for now.
9. SHORTING BAR INSTALLATION
Next, feed each shorting bar onto the pair of linear rod ends and position about them at the
measurement as shown on the DIMENSION SHEET. NOTE the dimension is measured from the
OUTSIDE edge of the LL arm to the OUTSIDE edge of the shorting bar. (USING A BLACK
PERMANENT MARKING PEN OR EQUIVALENT, MARK THE SPOT ON THE ROD WHERE THE
SHORTING BAR SHOULD BE) Be sure the linear loading lines are centered about the main element.
Once the shorting bars have been correctly set, align, and tighten all of the 8-32 hardware. Cut off the
excess material (if any) so that about 1” of rod extends beyond the shorting bar. Start a SHAFT
RETAINER onto each rod end (just to backup the clamping function). Push the retainers up against
the shorting bar. Repeat for all of the other element halves.
10. SUSPENSION OF PHYLLISTRAN TENSION LINES
At this point you might want to perform the remaining steps on a flat surface. Support the ends of each
element tip up so that it is at the same height as the center section. Next insert the phyllistrand
tension lines through their respective turnbuckles, around each thimble or cable eye, and then finally
back through the two cable clips. See the ELEMENT HARDWARE drawing for an illustration. Now
pull on the free end of the phyllistrand until the entire element appears to be level. (IT MAY BE
HELPFUL TO RAISE THE OUTER END OF THE ELEMENT HALF WITH A 4” BLOCK OF WOOD OR
BRICK. At this point, secure the tension line by tightening the two 1/8” cable clips. Repeat this
procedure for all the other element halves. The final tensioning of the linear loading rods is done with
the TURNBUCKLES. This can be performed after the elements have been secured to the boom.
11. BOOM ASSEMBLY
Use the BOOM HARDWARE drawing as a guide to assemble the boom. At this point it will be helpful
to perform the remaining assembly steps with the antenna elevated off the ground (about 3 feet). This
can be accomplished by using sawhorses or something similar. Wipe off the swaged ends of each
boom section and apply a small amount of Penetrox. Insert the swaged end of the boom sections into
the straight piece. Align all of the holes, install the 1/4-20 x 3-1/2" bolts and locknuts, and tighten.
Install the 5/16 x 5” eyebolts near each end of the boom.
40M3L ASSEMBLY MANUAL
